Cleaning and polishing article



United States Patent Office 3,171,151 Patented Mar. 2, 1965 The present invention relates to improved fibrous articles finding special utility in the maintenance of fioors and to the method of making such articles.

In the maintenance of floors, attempts have been made to utilize pads formed of animal, vegetable, mineral and synthetic fibrous materials bonded together by a suitable binder material and incorporating abrasive grains distributed throughout the fibrous pad.

Several difficulties arise in the use of such pads. In floor cleaning operations, aqueous solutions of such chemicals as caustic potash, ammonia, trisodium phosphate and the like are commonly used. Such solutions cause a rapid loss in the tensile strength, compression set and load deflection 'of these fibrous pads. This problem is particularly evident when animal fibers are utilized. The incorpooration of abrasive particles such as silicon carbide in such floor maintenance articles is of benefit where an aggressive action is required. However, such floor maintenance articles incorporating abrasive grits cannot be used in the polishing of fioors.

Accordingly, it is an object 'of the present invention to provide an improved fibrous article for use in floor maintenance operations not subject to the above-mentioned shortcomings and difficulties.

It is a further object of this invention to provide an improved fibrous article useful in the maintenance of floors which can be used both in cleaning and polishing operations in the maintenance of oors.

Further and additional objects of this invention will become apparent from the following specification in the accompanying drawings in which:

FIG. 1 is a partial diagrammatic view of a production line for producing the fiber pad of this invention; and

FIG. 2 is a perspective view of a liber pad embodying this invention; and

FIG. 3 is a sectional view of our improved fiber pad taken on the line 3-3 of FIG. 2.

In accordance with the present invention, we provide a stereoreticulate mass of curled organic fibers of substantially uniform thickness in the form of a pad. The bers of the pad are firmly bonded together Vat: points where they cross and contact one another by a vulcanized binder or elastomer. The fibers are also provided with a coating of a water-repellant material. The fiber pad of this invention performs a dual function. That is, it can be used both in the cleaning and polishing of floors. In such a pad one operable side of the pad is more aggressive, of greater density and of less resiliency than the opposite side of the pad.

The organic fibers used as a starting material in accordance with the present invention include the common Itypes of commercial animal hair, such as horse hair, cattle hair, and hog hair. Specifically desirable types of animal hair from both an economic and functional stand- Y point are relatively short hairs, such as hog hair. However, longer types of hair, such as cattle tail hair, horse mane hair, etc., can also be employed. Excellent results are obtained with hog hair which can contain a percentage of other types of hair, such as cattle tail hair. Preferably, the hair fibers have an average diameter of from about 2.0 to about 9.0 mils. Synthetic fibers such as nylon and dacron can also be utilized. The fibers employed preferably have a three dimensional curvature impressed upon them by a curling or crimping process. Such curling or crimping can be accomplished by mechanical means or by the more recently developed chemical curling processes. The curling or crimping of the fibers by either mechanical or Ychemical means introduces a three dimensional curl or crimp in the fibers so that a random distribution 'of the fibers on a fiat surface produces an approx- Vimate stereoreticulate mass.

The initial step in the production of the fiber pads involves the spreading of the curled organic fibers in a layer of the desired thickness. This can be accomplished mechanically and the fibers are allowed to fall on a horizontal surface so that it assumes a random distribution and forms a fibrous mat or web of a predetermined bulk density. For the preparation of pads used in oor maintenance operations, a finished web or pad from three quarters to two inches in thickness is preferred.

Referring to FIG. l of the drawing, there is shown in diagrammatic form the apparatus for carrying out the production of the floor maintenance pads. The curled fibers, for example, curled animal hair in hopper 10 is fed downwardly onto a slide 11 from which it is discharged into a fiber spreader 12. In FIG. l as illustrated, the liber spreader 12 is equipped with wiretoothed carding cylinders 13 and 14, which separate the fibers as they are discharged from the slide 11. The ber spreader 12 also includes two lower spreading rolls 15 and 16. The uiy mass of fibers 17 is discharged downwardly by the carding rolls 13 and 14 and spreading rolls 15 and 16 'onto a continuous conveyor belt 2 0 where it is formed into a web 18 of any desired thickness.

Following the formation of the flat fibrous mat or web, the web 18 passes beneath an interlacer 21. This interlacer is provided with a series of needlelike members 22, which needle members operate in a vertical plane and penetrate into the web 18. This operation serves to compact the upper portion of the web or pad 18 and it'is preferable that the needles penetrate to a depth of about three-fourths of the thickness of the web. Thus in the upper portion of the web the fibers will be of greater densityrthan the lower portion of the web. This upper portion by having a greater fiber density, is also less resilient than the lower half of the pad and is useful in scrubbing or cleaning operations.

Following the interlacing operation, the fiber mat or web 13 is sprayed with an elastomer for the purpose 0f bonding the fibers together. With webs of about threefourths (3A) to two (2) inches in thickness, Vit has been found desirable to spray the web a single time from each side. This gives best penetration by the liquid elastomer dispersion and prevents the dispersion from collecting on the conveyor or other supporting surface.

Referring again to FIG. l of the drawings, the web 18 is shown being carried toward the right from the interlacer 21 by conveyor belt 20 to a spraying station or zone 23 wherein one side of the web is sprayed with the liquid elastomer dispersion. In the illustration as shown, there is a spray head 24 which is preferably of the oscillating type so that it moves back and forth across the web during the spraying operation. Suf`u`cient elastomer is applied at spray station 23 to penetrate the upper half of the web. Thereafter, conveyor belt Y20 takes the partially` elastomer-coated web through a dryer zone 25 wherein the elastomer coating is dried t0 an indispersible but unvulcanized condition. 'Ihis operation increases the tensile strength of the mat so that it can be inverted without tearing and also so that the elastomer coating will not drain downwardly upon the conveyor belt when the web is inverted and cause the web to stick. The time required in the dryer zone 25 will be between. about 15 to 20 seconds when vthe dryer i of the hot -air blast type is utilized. The partially coated web 18 is then passed through a series of rollers 26 where the upper portion of web 18 is further cornpacted and densied.

The partially coated web 18 is then taken over an inverter 27 which turns the web over so that the uncoated portion of the web or mate is now uppermost on the conveyor 20. The mat is then conveyed through a second spraying TABLE II zone 28 similar to spraying zone 23. If desired, it, too can be equipped with an oscillating spray head 29 of the 10 r l sarne type as spray head 24. Sucient elastomer is apam Remnant Mammal Comment plied in this spray station 28 to penetrate to the center A q of the web and thus complete the distribution of the 1' loggiummum Formate som' These materials am especially Suit elastomer throughout the Well t Ssolnogrggf able for treating the iibers prior After the web 18 has been sprayed at station 28 1t 15 55472 omtheniplictwn 0f any das' is passed through a curing oven 31 where the elastomer 33@ g; ls-3- 0 er a e a' used to bond the fibers togfther Cured: The temper 6: Paroatin Wax Emulsioiis: u" These wax materials are particuatures employed in this curing oven are in the range of (a) CgnloJ-lbaiaixgatuek itrylastiiite fgfasiclgrepoitcrrii about 260 F. to 325 F. for from 4 to about 1() min- (b) Carbommx For' ths purpose, about 5.15' utes depending on the elastomer. glrllllllteliwn@ We grsttso gte??? lpsrd 100 parts 0f dry From the curing oven 31 the vulcanized web 18 is 7. One part of Street REP-100 This material is suitable for treat' passed updell a Cutimg press 32 whrem the: continuous dissolved in 6 parts of Stodingthe elastomer vulcanized pad. web 18 is die cut into pads of various shapes, such as dard Solvent. discs S. 10% solution of BMFC 805 The treated pad is dried in an oven (This material is composed o for about 10 minutes at 250 F. Following the cutting operation, the vulcanized pads 30% Fiuowehemieai, 60% are conveyed into tank 33 containing a suitable waterfrlll'* Water repellant solution. The iber pad is soaked in the solu- 9. 101g7 Fsoiuiiea ofdu Pont Zelan Th 1 1 d. tl 1 G a( S 3X0 D 510 lu 1050 SO lltlon for a period from 2 to 10 mmutes then removed 10. 10% solution ol du Pont Zclan tiorlis for about 10 minutes and allowed to drain, and then conveyed on to oven 34^to re- AP. dried at 250 F. for about 10 move any volatile solvent and to dry the pad. 11- lohsrggfooflggout Qullon mmutes' Various types of elastomer dispersions or binders can be employed in this invention. It is preferred to employ an aqueous dispersion of a vulcanizable elastomer. The re gltnlgriisai? Ofiriiergg tvllilethlitfeovilatl elastomer can be either a natural rubber or latex, a mi; adwhen tile adsare u2 d floor cleanin and synthetic elastomer latex, or va reclaimed rubber dis- 35 Scrubgn o erationsp but We hwe also discovere that persion. The rubber or synthetic elastomer dispersion the Wate rep @11am tre imam more com mel Channels is compounded with other ingredients to facilitate the the a'ueou pdeaninyo luti n us d in opr myhtenance application in curing of the elastomer. Water may be q. s 1 a so o s e o al. added to secure the re uired consstenc for a licatio'i operano thlough the pad thus Servmg the distribute S ecic exam les of elastomers Wh.ch Lm b pp 1 40 the solution to all the iibers resulting in a more thorough p p 1 e emp 'ye cleaning action. Additionally, this also functions in better include natural rubber, butadiene-styrene dispersions, cleansing of the pad itself neoilfene rubber dlSPCfSlOUS, Poll/Vinyl chlordm CC. FIGS. 2 and 3 of the drawings illustrate a preferred Typical formulae 0f Such compounded VlllCIllZable @13S- enibodiment of this invention. The bers in the upper tOnierS are Set out 1n Table I belOW portions 41 of this pad 40 are denser, less resilient and TABLE I FormulaA Formula B Formula() Formula D FormulaE (Dry Parts) (Dry Parts) (Dry Parts) (Dry Parts) (Dry Parts) N eoprciie 842A 9 68 75. 0-l25.0 Darvan #2 l 72 1.72 Caustic Potasli-- 0 15 0.15 Zinc Oxide. 1 31 17.31 O. GO 67 U. G7 35 0. 35 S5 0.85

Polyvinyl chloride (Geom 576) Acrotex M3 Aerotex AS Silican Carbide (Grade 180-600) Triton X-IOO Carbon black As shown in FIG. l, the water-repellant coating is applied to the liber pad after the pad has been completely sprayed with the suitable elastomer and passed through more agressive than are the bers in the lower portion 42l of the pad. In iioor maintenance operations the pad 4t),` which is shown in perspective in FIG. 2, is mounted to the curing oven. However, the watenrepellant materials any conventional rotary oor maintenance machine.

When it is desired to use this dual function pad in iioor cleaning or scrubbing, side 41 of the pad is mounted so as to be in contact with the floor surface. Correspondingly, if the pad is to be used in the polishing of oors, then the pad is mounted so that side 42 of pad 40 is in direct contact with the floor surface.

The invention can be further illustrated by the following examples:

Example l A web of curled animal hair ibers weighing approximately 4 ounces per square foot and comprising 80% hog hair and cattle tail hair was formed on a con- Veyor. The mat or web of curled hair was passed beneath an interlacer so adjusted that the needle penetration was approximately three-fourths of the thickness of the mat. Following the interlacing operation, the mat was sprayed with an aqueous dispersion of a neoprene rubber composition prepared according to Formula B, of Table I. Following the application of the elastomer, the mat was passed through a drying zone for about 20 seconds wherein a blast of hot air was directed over the mat to set the elastomer.

Thereafter, the partially coated mat was passed through a series of rollers to further compact and densify the upper portion of the mat.

The mat was then turned over so that the uncoated portion was uppermost on the conveyor and sprayed with an aqueous dispersion of a neoprene rubber composition prepared according to Formula A, of Table I. Thereafter, the sprayed mat was conveyed into a curing oven for about 6 minutes at approximately 290 F.

A series of discs (12 inches in diameter) was cut from the continuous mat and passed into a tank containing a solution of a Water-repellant material. This waterrepellant material consisted of one part of Street REP-100 dissolved in 6 parts of Stoddard solvent. The iiber discs remained in the water-repellant solution for about 6 minutes, removed, allowed to drain and thereafter conveyed through an oven to remove any volatile solvent and to dry the pad. The iinished pad had a thickness of 1.25 inches and weighed approximately 8 ounces per square foot.

Example Il Fiber pads were made in the same manner as in Example I with the exception that an aqueous dispersion of a natural rubber composition prepared according to Formula C, Table I, was sprayed on the side of the mat wherein the fibers had been previously densiiied by interlacing. The opposite side of the mat was sprayed with an aqueous dispersion of a natural rubber composition prepared according to Formula D, Table I.

While in the foregoing specilication this invention has been described in considerable detail, it will be apparent to those skilled in the art that many of the specific details and embodiments can be varied widely without departing from the broad idea of the invention.

We claim:

1. A cleansing and polish-ing article comprising a stereoreticulate mass of curled organic fibers in the form of a reversible pad of substantially uniform thickness having two opposed operable sides, said fibers being bonded together at points where they cross and contact one another by a vulcanized elastomer, one operable side of said pad being of uniformly greater fiber density and of less resiliency than the opposite operable side of said pad.

2. A cleansing and polishing article comprising a stereoreticulate mass of curled organic fibers in the -form of a pad having two opposed operable sides, said fibers being bonded together at points Where they cross and contact one another by vulcanized elastomer, one operable side of said pad being of greater density and of less resiliency than the opposite operable side of said pad, said bers having a coating of a water-repellant material.

3. The article of claim 2 wherein said water-repellant material is incorporated into said vulcanized elastomer.

4. A cleansing and polishing Varticle comprising a stereoreticulate mass of curled hair fibers in the form of a reversible pad of substantially uniform thickness and having two opposed operable sides, said fibers having a coating of a water-repellant water and being bonded together at points where they cross and contact one another by a vulcanized elastomer, one operable side of said pad being of greater density and of less resiliency than the opposite operable side of said pad.

References Cited in the le of this patent UNITED STATES PATENTS 1,334,744 Farr Mar. 23, 1920 1,873,030 Quinn Aug. 23, 1932 2,375,585 Rimer May 8, 1945 2,526,468 Frye Oct. 17, 1950 2,803,577 Colt et al Aug. 20, 1957 2,958,593 Hoover et al Nov. 1, 1960 FOREIGN PATENTS 181,389 Austria Mar. 10, 1955 

1. A CLEANSING AND POLISHING ARTICLE COMPRISING A STEREORETICULATE MASS OF CURLED ORGANIC FIBERS IN THE FORM OF A REVERSIBLE PAD OF SUBSTANTIALLY UNIFORM THICKMESS HAVING TWO OPPOSED OPERABLE SIDES, SAID FIBERS BEING BONDED TOGETHER AT POINTS WHERE THEY CROSS AND CONTACT ONE ANOTHER BY A VULCANIZED ELASTOMER, ONE OPERABLE SIDE OF SAID PAD BEING OF UNIFORMLY GREATER FIBER DENSITY AND OF LESS RESILIENCY THAN THE OPPOSITE OPERABLE SIDE OF SAID PAD. 